Electrical connections for electro-optic elements

ABSTRACT

An electro-optic element of a display of a vehicle includes a first substantially transparent substrate defining a first surface and a second surface. A first edge extends around the first substrate. A second substantially transparent substrate defines a third surface and a fourth surface. A second edge extends around the second substrate. A primary seal is disposed between the first and second substrates. The seal and the first and second substrates define a cavity therebetween. At least one of the first and second edges is stepped proximate the seal to define a channel. An electro-optic material is positioned within the cavity.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to and the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application No. 62/435,922, filed onDec. 19, 2016, entitled ELECTRICAL CONNECTIONS FOR ELECTRO-OPTICELEMENTS, the entire disclosure of which is hereby incorporated hereinby reference.

FIELD OF THE DISCLOSURE

The present disclosure generally relates to electro-optic elements, andmore particularly, to electrical connections for electro-optic elements.

BACKGROUND OF THE DISCLOSURE

Electro-optic elements are being used in various vehicular and buildingapplications, (e.g., within rearview display devices and variablytransmissive windows). Use of these assemblies in various applicationscan be limited by cost, aesthetic and functional considerations.Accordingly, new electro-optic element designs, configurations andassemblies, along with methods of making them, are needed particularlyin view of reducing material and processing costs, improving aestheticsand/or enhancing functionality.

SUMMARY OF THE DISCLOSURE

According to at least one feature of the present disclosure, anelectro-optic element of a display of a vehicle includes a firstsubstantially transparent substrate defining a first surface and asecond surface. A first edge extends around the first substrate. Asecond substantially transparent substrate defines a third surface and afourth surface. A second edge extends around the second substrate. Aprimary seal is disposed between the first and second substrates. Theseal and the first and second substrates define a cavity therebetween.At least one of the first and second edges is stepped proximate the sealto define a channel. An electro-optic material is positioned within thecavity.

According to another feature of the present disclosure, an electro-opticelement includes a first substantially transparent substrate defining afirst surface and a second surface. A first edge extends around thefirst substrate. A second substantially transparent substrate defines athird surface and a fourth surface. A second edge extends around thesecond substrate. A primary seal is disposed between the first andsecond substrates. The seal and the first and second substrates define acavity therebetween. The cavity has a thickness between the first andsecond substrates of less than about 75 μm and the second edge isstepped in an inboard direction to define a channel. An electro-opticmaterial is positioned within the cavity.

According to another feature of the present disclosure, an electro-opticelement includes a first substantially transparent substrate defining afirst surface and a second surface. A first edge extends around thefirst substrate. A second substantially transparent substrate defines athird surface and a fourth surface. A second edge extends around thesecond substrate. The second edge is set inboard of the first edge todefine a channel. A conductive bus is positioned within the channel. Aprimary seal is disposed between the first and second substrates. Theseal and the first and second substrates define a cavity. Anelectro-optic material is positioned within the cavity.

These and other features, advantages, and objects of the presentdisclosure will be further understood and appreciated by those skilledin the art by reference to the following specification, claims, andappended drawings.

According to a first aspect, an electro-optic element of a display of avehicle is provided that includes an electro-optic element of a displayof a vehicle includes a first substantially transparent substratedefining a first surface and a second surface. A first edge extendsaround the first substrate. A second substantially transparent substratedefines a third surface and a fourth surface. A second edge extendsaround the second substrate. A primary seal is disposed between thefirst and second substrates. The seal and the first and secondsubstrates define a cavity therebetween. At least one of the first andsecond edges is stepped proximate the seal to define a channel. Anelectro-optic material is positioned within the cavity.

According to a second aspect, the electro-optic element of aspect 1 isprovided, wherein the second edge is stepped in an inboard direction todefine the channel.

According to a third aspect, the electro-optic element of aspect 1further comprises, an electrical bus positioned within the channel.

According to a fourth aspect, the electro-optic element of aspect 1 isprovided, wherein both the first and second edges are stepped to definethe channel.

According to a fifth aspect, the electro-optic element of aspect 4further comprises, a first electrical bus positioned proximate the firststepped edge; and a second electrical bus positioned proximate thesecond stepped edge, wherein the first and second electrical buses areelectrically isolated.

According to a sixth aspect, the electro-optic element of aspect 5,wherein the seal is positioned between the first and second electricalbuses.

According to a seventh aspect, the electro-optic element of aspect 1,wherein the cavity has a spacing between about 20 μm and about 75 μm.

According to an eighth aspect of the electro-optic element of aspect 1,wherein an electrical connection extends into the channel, theelectrical connection comprises a polymeric film with a metalliccoating.

According to a ninth aspect of the electro-optic element of aspect 1,wherein an electrical connection extends into the channel and athickness of the electrical connection is greater than a spacing of thecavity.

According to a tenth aspect, an electro-optic element is provided thatincludes a first substantially transparent substrate defining a firstsurface and a second surface. A first edge extends around the firstsubstrate. A second substantially transparent substrate defines a thirdsurface and a fourth surface. A second edge extends around the secondsubstrate. A primary seal is disposed between the first and secondsubstrates. The seal and the first and second substrates define a cavitytherebetween. The cavity has a thickness between the first and secondsubstrates of less than about 75 μm and the second edge is stepped in aninboard direction to define a channel. An electro-optic material ispositioned within the cavity.

According to an eleventh aspect, the electro-optic element of aspect 10further comprises a conductive bus positioned within the channel andextending substantially over the second edge.

According to a twelfth aspect, the electro-optic element of aspect 10 isprovided, wherein the seal is positioned inboard of the channel.

According to a thirteenth aspect, the electro-optic element of aspect 12is provided, wherein the channel is wider than it is tall.

According to a fourteenth aspect, the electro-optic element of aspect 12is provided, wherein the channel is taller than it is wide.

According to a fifteenth aspect, the electro-optic element of aspect 10is provided, wherein the electro-optic material is an electrochromicmaterial.

According to a sixteenth aspect, the electro-optic element of aspect 10is provided, wherein an electrical bus is positioned within the channeland extends substantially around the second substrate.

According to a seventeenth aspect, the electro-optic element of aspect10 is provided, wherein the first edge is stepped in an inboarddirection such that the channel is defined by the first and secondstepped edges and an electrical bus substantially fills the channel.

According to an eighteenth aspect, the electro-optic element is providedthat includes a first substantially transparent substrate defining afirst surface and a second surface. A first edge extends around thefirst substrate. A second substantially transparent substrate defines athird surface and a fourth surface. A second edge extends around thesecond substrate. The second edge is set inboard of the first edge todefine a channel. A conductive bus is positioned within the channel. Aprimary seal is disposed between the first and second substrates. Theseal and the first and second substrates define a cavity. Anelectro-optic material is positioned within the cavity.

According to a nineteenth aspect, the electro-optic element of aspect 18is provided, wherein the conductive bus defines a curved shape.

According to a twentieth aspect, the electro-optic element of aspect 19is provided, wherein the conductive bus comprises a silver epoxy.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a perspective view of a passenger compartment of a vehicleincluding an electro-optic element, according to at least one example;

FIG. 2 is a cross-sectional view of the electro-optic element, accordingto at least one example;

FIG. 3 is a cross-sectional view of the electro-optic element, accordingto at least one example;

FIG. 4 is a cross-sectional view of the electro-optic element, accordingto at least one example;

FIG. 5A is a cross-sectional view of the electro-optic element,according to at least one example;

FIG. 5B is a cross-sectional view of the electro-optic element,according to at least one example; and

FIG. 6 is a cross-sectional view of the electro-optic element, accordingto at least one example.

DETAILED DESCRIPTION OF EMBODIMENTS

Additional features and advantages of the invention will be set forth inthe detailed description which follows and will be apparent to thoseskilled in the art from the description, or recognized by practicing theinvention as described in the following description, together with theclaims and appended drawings.

As used herein, the term “and/or,” when used in a list of two or moreitems, means that any one of the listed items can be employed by itself,or any combination of two or more of the listed items can be employed.For example, if a composition is described as containing components A,B, and/or C, the composition can contain A alone; B alone; C alone; Aand B in combination; A and C in combination; B and C in combination; orA, B, and C in combination.

In this document, relational terms, such as first and second, top andbottom, and the like, are used solely to distinguish one entity oraction from another entity or action, without necessarily requiring orimplying any actual such relationship or order between such entities oractions. The terms “comprises,” “comprising,” or any other variationthereof, are intended to cover a non-exclusive inclusion, such that aprocess, method, article, or apparatus that comprises a list of elementsdoes not include only those elements but may include other elements notexpressly listed or inherent to such process, method, article, orapparatus. An element preceded by “comprises . . . a” does not, withoutmore constraints, preclude the existence of additional identicalelements in the process, method, article, or apparatus that comprisesthe element.

Referring to FIGS. 1-4, reference numeral 10 generally designates anelectro-optic element 10. The electro-optic element 10 may be utilizedin a display 14 of a vehicle. A first substantially transparentsubstrate 18 defines a first surface 18A and a second surface 18B. Afirst edge 18C extends around the first substrate 18. A secondsubstantially transparent substrate 22 defines a third surface 22A and afourth surface 22B. A second edge 22C extends around the secondsubstrate 22. A primary seal 26 is disposed between the first and secondsubstrates 18, 22. The seal 26 and the first and second substrates 18,22 define a cavity 30 therebetween. At least one of the first and secondedges 18C, 22C is stepped proximate the seal 26 to define a channel 34.An electro-optic material 38 is positioned within the cavity 30.

With regard to FIG. 1, the electro-optic element 10 may be included invarious displays 14 for a vehicle 42. The display 14 may be implementedas an interior rearview display 46, a side-mirror display 50, and/orvarious other mirrored devices. Though discussed in reference to anautomotive vehicle, the electro-optic element 10 and/or display 14 maybe utilized for various applications including, but not limited to,transit vehicles, nautical vessels, aircraft, etc. In some examples, theelectro-optic element 10 and/or display 14 may be implemented as aheads-up display 54, which may be affixed or laminated to a windscreen58 of the vehicle 42. In such a configuration, the electro-optic element10 discussed herein may be configured to be transitioned betweensubstantially transparent and substantially darkened states. Such aconfiguration may be used to selectively control the transmittance ofthe electro-optic element 10 to control a contrast between thewindscreen 58 and the display 14. Enhanced contrast may improve avisibility of image data and/or graphics displayed on the display 14. Inheads-up display 54 examples, the heads up display 54 may correspond toa standalone device that may be mounted or attached to a dashboard orconsole of the vehicle 42. In such examples, the heads-up display 54 maycorrespond to a pop-up display that may be selectively extended orretracted from a dashboard or instrument panel of the vehicle 42.

Referring now to FIG. 2, in the depicted example, the electro-opticelement 10 includes the first and second substrates 18, 22. The firstand/or second substrates 18, 22 may be composed of a substantiallytransparent material such as glass (e.g., soda lime glass), a polymericmaterial (e.g., acrylic and/or polycarbonate), or combinations thereof.The first substrate 18 may have a thickness of less than or equal toabout 2.2 mm, 2.0 mm, 1.6 mm, 1.5 mm, 1.2 mm, 1.0 mm, or 0.4 mm. Thefirst substrate 22 may take a variety of shapes including square,rectangular, circular, oblong and combinations thereof. According tovarious examples, the first and/or second substrates 18, 22 may have acurvature across the length or width (i.e., a vertical or horizontalaxis). In the depicted example, positioned on the second and thirdsurfaces 18B, 22A are respective first and second electricallyconductive layers 62, 66. The first and second electrically conductivelayers 62, 66 may include a transparent conductor such as a transparentmetal oxide (e.g., indium-tin-oxide, F:SnO₂, ZnO, IZO), carbon (grapheneand/or graphite) and/or a conductive metal mesh (e.g., nanowires). Inindium-tin-oxide examples, the first and second electrically conductivelayers 62, 66 may have a sheet resistance of between about 1 ohms/sq andabout 100 ohms/sq. The first and second electrically conductive layers62, 66 may each define an isolation area 64 (FIG. 3). The isolation area64 of the first electrically conductive layer 62 separates the firstelectrically conductive layer 62 into a first portion 62A and a secondportion 62B. The first and second portions 62A, 62B may be electricallyisolated from one another. The isolation area 64 of the secondelectrically conductive layer 66 separates the second electricallyconductive layer 66 into a third portion 66A and a fourth portion 66Bwhich may be electrically isolated from one another. According tovarious examples, a spectral filter, or chrome ring, may be utilized toobscure the isolation area 64 and/or channels and buses as described ingreater detail below.

The first and second substrates 18, 22 can be positioned in a parallelrelationship and sealed around the perimeter using the primary seal 26to define the cavity 30 (FIG. 4). The seal 26 extends around the secondand third surfaces 18B, 22A to confine the electro-optic material 38between the first and second substrates 18, 22. The seal 26 may bepositioned proximate to, or in contact with, the isolation areas 64.Additional information related to forming a seal between a first andsecond substrate can be found in U.S. Pat. No. 5,790,298, entitled“METHOD OF FORMING OPTICALLY TRANSPARENT SEAL AND SEAL FORMED BY SAIDMETHOD,” which is hereby incorporated herein by reference in itsentirety. The cavity 30 may have a spacing between the first and secondsubstrates 18, 22 of less than or equal to about 100 μm, 90 μm, 75 μm,50 μm, 40 μm 35 μm, or less than or equal to about 20 μm. In a specificexample, the spacing may be between about 20 μm and about 75 μm.

According to one example, the electro-optic element 10 may be a liquidcrystal device, including a liquid crystal medium (e.g., theelectro-optic material 38), configured to attenuate light transmittedthrough the electro-optic element 10 and/or display 14. In anotherexample, the electro-optic element 10 may be a suspended particledevice. In yet another example, the electro-optic element 10 may be anelectrochromic element. In such an example, the electro-optic material38 of the electro-optic element 10 is an electrochromic medium whichincludes at least one solvent, at least one anodic material, and atleast one cathodic material. Typically, both of the anodic and cathodicmaterials are electroactive and at least one of them is electrochromic.It will be understood that regardless of its ordinary meaning, the term“electroactive” may mean a material that undergoes a modification in itsoxidation state upon exposure to a particular electrical potentialdifference. Additionally, it will be understood that the term“electrochromic” may mean, regardless of its ordinary meaning, amaterial that exhibits a change in its extinction coefficient at one ormore wavelengths upon exposure to a particular electrical potentialdifference. Electrochromic components, as described herein, includematerials whose color or opacity are affected by electric current, suchthat when an electrical current is applied to the material, the color oropacity changes from a first phase to a second phase. The electrochromiccomponent may be a single-layer, single-phase component, multi-layercomponent, or multi-phase component, as described in U.S. Pat. No.5,928,572 entitled “ELECTROCHROMIC LAYER AND DEVICES COMPRISING SAME,”U.S. Pat. No. 5,998,617 entitled “ELECTROCHROMIC COMPOUNDS,” U.S. Pat.No. 6,020,987 entitled “ELECTROCHROMIC MEDIUM CAPABLE OF PRODUCING APRE-SELECTED COLOR,” U.S. Pat. No. 6,037,471 entitled “ELECTROCHROMICCOMPOUNDS,” U.S. Pat. No. 6,141,137 entitled “ELECTROCHROMIC MEDIA FORPRODUCING A PRE-SELECTED COLOR,” U.S. Pat. No. 6,241,916 entitled“ELECTROCHROMIC SYSTEM,” U.S. Pat. No. 6,193,912 entitled “NEARINFRARED-ABSORBING ELECTROCHROMIC COMPOUNDS AND DEVICES COMPRISINGSAME,” U.S. Pat. No. 6,249,369 entitled “COUPLED ELECTROCHROMICCOMPOUNDS WITH PHOTOSTABLE DICATION OXIDATION STATES,” and U.S. Pat. No.6,137,620 entitled “ELECTROCHROMIC MEDIA WITH CONCENTRATION ENHANCEDSTABILITY, PROCESS FOR THE PREPARATION THEREOF AND USE IN ELECTROCHROMICDEVICES”; U.S. Patent Application Publication No. 2002/0015214 A1entitled “ELECTROCHROMIC DEVICE”; and International Patent ApplicationSerial Nos. PCT/US98/05570 entitled “ELECTROCHROMIC POLYMERIC SOLIDFILMS, MANUFACTURING ELECTROCHROMIC DEVICES USING SUCH SOLID FILMS, ANDPROCESSES FOR MAKING SUCH SOLID FILMS AND DEVICES,” PCT/EP98/03862entitled “ELECTROCHROMIC POLYMER SYSTEM,” and PCT/US98/05570 entitled“ELECTROCHROMIC POLYMERIC SOLID FILMS, MANUFACTURING ELECTROCHROMICDEVICES USING SUCH SOLID FILMS, AND PROCESSES FOR MAKING SUCH SOLIDFILMS AND DEVICES,” which are herein incorporated by reference in theirentirety. According to various examples, the electro-optic element 10may be configured to fail in a transparent state such that in the eventof failure, the display 14 may still be usable. Use of electrochromicexamples of the electro-optic element 10 may be advantageous becauseelectrochromics may have a very wide gray scale. Further, the gray scaleof the electrochromics may be angle independent such that the perceiveddarkening of the electro-optic element 10 does not vary as a drivershifts their perspective of the display 14 and/or electro-optic element10.

Still referring to FIG. 2, in the depicted example, the second edge 22Cof the second substrate 22 is stepped to define the channel 34. In thedepicted example, the second edge 22C of the second substrate 22 isstepped, or notched, in an inboard direction, or in a direction toward acenter of the electro-optic element 10 to define the channel 34. Inother words, the channel 34 of the second substrate 22 extends inwardlyaway from the second edge 22C. The channel 34 is defined proximate thethird surface 22A, the primary seal 26 and/or the cavity 30.

In the depicted example, the stepped second edge 22C defines a firstchannel surface 34A and a second channel surface 34B which cooperate todefine the channel 34, but it will be understood that the first andsecond channel surfaces 34A, 34B may be a single, unitary, surface(e.g., in curved, semi-circular, or irregular shaped channel 34).Further, the channel 34 may include more than two surfaces (e.g., three,four or greater than four surfaces). According to some examples, thefirst channel surface 34A may be longer than the second channel surface34B such that the channel 34 is wider (e.g., in an inboard direction)than the channel 34 is tall (e.g., a distance into the thickness of thesecond substrate 22). According to other examples, the first channelsurface 34A may be shorter than the second channel surface 34B such thatthe channel 34 is taller (e.g., a distance into the thickness of thesecond substrate 22) than the channel 34 is wide (e.g., in an inboarddirection). The first channel surface 34A may have a width of greaterthan or equal to about 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm,0.7 mm, 0.8 mm, 0.9 mm or greater than or equal to about 1.0 mm. Thesecond channel surface 34B may have a height of greater than or equal toabout 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm,0.9 mm or greater than or equal to about 1.0 mm. It will be understoodthat the first and second channel surfaces 34A, 34B may have anycombination of widths (e.g., less than about 0.1 mm or greater thanabout 1.0 mm) that will produce a cross-sectional area and/or volumewhich is desired. An interface between the first and second channelsurfaces 34A, 34B may be at a right angle, may be defined by a radius,or may be an irregular shape. For example, the interface may be a radiussuch that first and second channels surfaces 34A, 34B are actually asingle continuous surface. In examples, where there are greater than twochannel surfaces, the surfaces may be arranged to form a step pattern(e.g., a plurality of smaller steps) within the channel 34 each havingan interface which may be defined by an angle and/or a radius. Further,it will be understood that although depicted with substantially rightangles, the interfaces between the third surface 22A, the second edge22C and the channel surfaces 34A, 34B may have a radius or other shapeto reduce stress concentration at the interfaces. Further, either orboth of the first and second channel surfaces 34A, 34B may be chamfered.

In the depicted example, the channel 34 is continuous around the secondedge 22C of the second substrate 22. It will be understood that thechannel 34 may be discontinuous (e.g., composed of two of channels 34)around the second edge 22C. Further, the channel 34 may extend aroundonly a portion of the second surface 22C of the second substrate 22. Thefirst and second channel surfaces 34A, 34B may vary across the length ofthe channel 34. For example, one portion of the channel 34 may have afirst cross-sectional area, and a second portion of the channel 34 mayhave a second cross-sectional area which is smaller, larger or the same(i.e., with different values of the first and second channel surfaces34A, 34B than the first portion) as the first cross-sectional area.

An electrical bus 78 may be positioned within the channel 34. Theelectrical bus 78 may be formed from an electrically conductivematerial, conductive solder, a conductive epoxy (e.g., silver epoxy), awire, an electrically conductive tab (e.g., a solid metal piece) orcombinations thereof. In the depicted example, the electrical bus 78includes a first bus portion 78A and a second bus portion 78B. The firstand second bus portions 78A, 78B may be electrically connected orisolated from one another. The first bus portion 78A extends through thechannel 34 and along the seal 26 to electrically contact the thirdportion 66A of the second electrically conductive layer 66 and the firstportion 62A of the first electrically conductive layer 62. The secondbus portion 78B extends through the channel 34 and next to the seal 26to electrically contact the fourth portion 66B of the secondelectrically conductive layer 66 and the second portion 62B of the firstelectrically conductive layers 62. The first and second bus portions78A, 78B each extend around a portion of a perimeter of theelectro-optic element 10 within the channel 34. The first and second busportions 78A, 78B may fully fill or partially fill the channel 34. Inthe depicted example, the bus portions 78A, 78B fully fill the channel34 and are substantially flush, or planar with the first and secondedges 18C, 22C. In other examples, the electrical bus portions 78A, 78Bmay only partially fill the channel 34 (e.g., proximate the first andsecond electrically conductive layers 62, 66). It will be understoodthat although depicted as flush with the channel 34, the electrical bus78 may extend between the first and second electrically conductive layer62, 66 (i.e., in an inboard direction) to increase the amount ofelectrical contact between the bus 78 and the first and secondelectrically conductive layers 62, 66. Further, in some examples, theelectrical bus portions 78A, 78B are positioned within the channel 34and extend substantially over the second edge 22C.

The electro-optic element 10 may include first and second electricalconnections 82A, 82B. In the depicted example, the first and secondelectrical connections 82A, 82B are positioned within the first andsecond bus portions 78A, 78B of the electrical bus 78, respectively. Itwill be understood that the first and second electrical connections 82A,82B may extend into the channel 34, or may be in contact with portionsof the first and second bus portions 78A, 78B which are external to thechannel 34. The first and second electrical connections 82A, 82B areconfigured to transmit electrical energy to the respective first andsecond bus portions 78A, 78B. In the depicted example, the first andsecond electrical connections 82A, 82B are configured as J-clips whichwrap around the second edge 22C and extend onto the fourth surface 22B.It will be understood that the electrical connection 82 may take avariety of configurations, including wires, metallized films, and otherelectrically conductive materials as described in greater detail below.Use of the channel 34 may be advantageous in increasing thecross-sectional area and/or volume of the first and second bus portions78A, 78B while maintaining a small cavity 30 spacing. Increasing thecross-sectional area and/or volume of the first and second bus portions78A, 78B may be advantageous in decreasing a resistivity of the firstand second bus portions 78A, 78B.

According to various examples, the second electrically conductive layer66 may extend into the channel 34. For example, the second electricallyconductive layer 66 may be applied (e.g., sputtering, chemical vapordeposition, electroplating, sprayed) onto the first and second channelsurfaces 34A, 34B. Such an example may be advantageous in increasing theelectrical connection between the conductive bus 78 and the secondelectrically conductive layer 66.

Referring now to FIG. 3, in the depicted example, the second substrate22 defines the channel 34 and the first substrate 18 defines a secondchannel 90. The second channel 90 may have substantially the samedimensions as the channel 34 of the second substrate 22. Similarly tothe second edge 22C of the second substrate 22, the first edge 18C ofthe first substrate 18 may be stepped, or notched, in an inboarddirection toward a center of the electro-optic element 10 to define thesecond channel 90. In the depicted example, the first and second busportions 78A, 78B extend upward into the second channel 90. The firstbus portion 78A extends through the channel 34 and the second channel 90to electrically contact the third portion 66A of the second electricallyconductive layer 66 and the first portion 62A of the first electricallyconductive layer 62. The second bus portion 78B extends through thechannel 34 and the second channel 90 to electrically contact the fourthportion 66B of the second electrically conductive layer 66 and thesecond portion 62B of the first electrically conductive layers 62. Thefirst and second bus portions 78A, 78B may fill or partially fill one orboth of the channel 34 and the second channel 90. In the depictedexample, the first and second bus portions 78A, 78B fill both thechannel 34 and the second channel 90 such that the first and second busportions 78A, 78B are substantially planar with both the first andsecond edges 18C, 22C. It will be understood that the first and secondbus portions 78A, 78B may fill different proportions of the channel 34and second channel 90. For example, the first bus portion 78A may beflush, or planar, with the first edge 18C, but not the second edge 22C,and the second bus portion 78B may be flush with the second edge 22C,but not the first edge 18C. Use of the second channel 90 may beadvantageous in essentially doubling the volume through which the firstand second bus portions 78A, 78B may extend. By utilizing the channel 34and the second channel 90, the cross-sectional area of each may bereduced (i.e., because the total cross-sectional area for the first andsecond bus portions 78A, 78B may be spread across the channel 34 andsecond channel 90). It will be understood that the first electricallyconductive layer 62 may be applied to the second channel 90 in a similarmanner as described above in connection with the channel 34 and thesecond electrically conductive layer 66.

Referring now to FIG. 4, in the depicted example, each of the channel 34and the second channel 90 include separate electrical buses 78. In thedepicted example, a first electrical bus 78C is positioned in the firstchannel 34, and a second electrical bus 78D is positioned in the secondchannel 90. The first and second electrical buses 78C, 78D may beelectrically isolated from one another. The first and second electricalbuses 78C, 78D may extend around a perimeter of the electro-opticelement 10 as a unitary structure or a discontinuous structure.Electrical isolation of the first and second electrical buses 78C, 78Dmay be accomplished via separation from one another, extending the seal26 between the buses 78, or through use of the first and secondelectrical connections 82A, 82B as shown. In the depicted example, thefirst and second electrical connections 82A, 82B are depicted as adual-coated film. In dual-coated film examples, the first and secondelectrical connections 82A, 82B may include a first conductive coating82C and a second conductive coating 82D positioned on opposite sides ofan insulator layer 82E. According to various examples, the first andsecond conductive coatings 82C, 82D may include a metallic or otherconducive material. For example, the first and second conductivecoatings 82C, 82D may include silver, gold, copper, aluminum, conductivemetals, conductive metal alloys, and/or combinations thereof. Theinsulator layer 82E may include a polymeric or semiconductor materialconfigured to electrically isolate the first and second conductivecoatings 82C, 82D. The insulator layer 82E may include polyethylene,polypropylene, polyimide polymers, other insulating polymers which areflexible, and/or combinations thereof. The insulator layer 82E may be apolymeric film. The first and second conductive coatings 82C, 82D areeach configured to carry electrical energy to one of the first andsecond electrical buses 78C, 78D. The dual coated film example of thefirst and second electrical connections 82A, 82B may be positionedbetween the first and second electrical buses 78C, 78D to both provideelectrical energy and to insulate the first and second electrical buses78C, 78D. Isolation of the first and second electrical connections 82C,82D may allow for the elimination of the isolation areas 64 (FIG. 3).

Referring now to the depicted examples in FIGS. 5A and 5B, according tovarious examples, one of the first (FIG. 5A) and second (FIG. 5B)substrates 18, 22 may be wider, or longer, than the other. In suchexamples, the channel 34 (FIG. 2) and the second channel 90 (FIG. 3) maynot need to be defined by the second and first substrates 22, 18,respectively. It will be understood that either substrate 18, 22 maystill define the channel 34 or the second channel 90 without departingfrom the teachings provided herein. Further, the channel 34 and/orsecond channel 90 may instead be defined by the second or third surface18B, 22A inboard of the first and second edges 18C, 22C. In suchexamples, the first and second bus portions 78A, 78B may extend alongnon-stepped examples of one of the first and second edges 18C, 22C. Asdepicted in FIG. 5A, the first substrate 18 is wider than the secondsubstrate 22 such that an overhang by the first substrate 18 is created.In the depicted example of FIG. 5A, the first and second bus portions78A, 78B extend from the first electrically conductive layer 62 and arein contact with the second edge 22C of the second substrate 22. In thedepicted example of FIG. 5B, the second substrate 22 is wider than thefirst substrate 18. In such an example, the first and second busportions 78A, 78B extend from the second electrically conductive layer66 toward the first substrate 18 and make contact with the first edge18C. In the depicted examples, the conductive buses 78 each define acurved exterior surface 78E (i.e., a curved shape). The curved exteriorsurfaces 78E curve inwardly (i.e., in an inboard direction) toward theelectro-optic element 10 to define an aesthetically pleasing appearance.The curved exterior surfaces 78E may curve to intersect the fourthsurface 22B (FIG. 5A) or to intersect the first surface 18A (FIG. 5B).It will be understood that the first and second electrical connections82A, 82B (FIG. 3) may be electrically coupled with the first and secondbus portions 78A, 78B as explained above. Use of the dimensionallymismatched first and second substrates 18, 22 may be advantageous ineliminating the use of the channel 34 and the second channel 90.

Referring now to FIG. 6, the electro-optic element 10 may not includethe electrical buses 78 (FIG. 5B), but may instead only include the dualfilm example of the first and second electrical connections 82A, 82B. Insuch an example, the first and second conductive coatings 82A, 82B maybe sufficiently thick to contact the first and second electricallyconductive layers 62, 66 without the use of the electrical buses 78.Such an example may be advantageous in reducing manufacturing time andcost associated with forming the channel 34 (FIG. 3), second channel 90(FIG. 3) as well as the first and second bus portions 78A, 78B (FIG. 3).Further, small cavity 30 spacings may still be achieved.

Use of the present disclosure may offer a variety of advantages. First,utilizing the channel 34 and/or second channel 90 may allow for a largercross-sectional area and/or volume to be achieved regardless of size orspacing of the cavity 30. As the size of the cavity 30 is decreased(i.e., as the distance between the first and second substrates 18, 22 isdecreased) the area for the electrical bus 78 may be decreased, whichmay result in an increased resistance. Use of the channel 34 and/orsecond channel 90 may allow for an increased area for the electrical bus78 such that the resistance is decreased while allowing a thinner cavity30. Second, use of the dual coated film examples of the first and secondelectrical connections 82A, 82B, with or without the channel 34 and/orsecond channel 90, may also allow for the thinning of the cavity 30. Forexample, the dual-coated film examples of the first and secondelectrical connections 82A, 82B may be able to fit between thin cavity30 examples of the electro-optic element 10 where conventionalelectrical connections 82 (e.g., J-clips) may not be able to fit. Third,use of the present disclosure offers a flexibility in design of theelectro-optic element 10 with respect to thickness and electricalconnection. Fourth, use of the present disclosure may reduce a thicknessof a chrome ring or spectral filter width.

Modifications of the disclosure will occur to those skilled in the artand to those who make or use the disclosure. Therefore, it is understoodthat the embodiments shown in the drawings and described above aremerely for illustrative purposes and not intended to limit the scope ofthe disclosure, which is defined by the following claims, as interpretedaccording to the principles of patent law, including the doctrine ofequivalents.

It will be understood by one having ordinary skill in the art thatconstruction of the described disclosure, and other components, is notlimited to any specific material. Other exemplary embodiments of thedisclosure disclosed herein may be formed from a wide variety ofmaterials, unless described otherwise herein.

For purposes of this disclosure, the term “coupled” (in all of itsforms: couple, coupling, coupled, etc.) generally means the joining oftwo components (electrical or mechanical) directly or indirectly to oneanother. Such joining may be stationary in nature or movable in nature.Such joining may be achieved with the two components (electrical ormechanical) and any additional intermediate members being integrallyformed as a single unitary body with one another or with the twocomponents. Such joining may be permanent in nature, or may be removableor releasable in nature, unless otherwise stated.

It is also important to note that the construction and arrangement ofthe elements of the disclosure, as shown in the exemplary embodiments,is illustrative only. Although only a few embodiments of the presentinnovations have been described in detail in this disclosure, thoseskilled in the art who review this disclosure will readily appreciatethat many modifications are possible (e.g., variations in sizes,dimensions, structures, shapes and proportions of the various elements,values of parameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter recited. For example,elements shown as integrally formed may be constructed of multipleparts, or elements shown as multiple parts may be integrally formed, theoperation of the interfaces may be reversed or otherwise varied, thelength or width of the structures, and/or members, or connectors, orother elements of the system, may be varied, and the nature or numeralof adjustment positions provided between the elements may be varied. Itshould be noted that the elements and/or assemblies of the system may beconstructed from any of a wide variety of materials that providesufficient strength or durability, in any of a wide variety of colors,textures, and combinations. Accordingly, all such modifications areintended to be included within the scope of the present innovations.Other substitutions, modifications, changes, and omissions may be madein the design, operating conditions, and arrangement of the desired andother exemplary embodiments without departing from the spirit of thepresent innovations.

It will be understood that any described processes, or steps withindescribed processes, may be combined with other disclosed processes orsteps to form structures within the scope of the present disclosure. Theexemplary structures and processes disclosed herein are for illustrativepurposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can bemade on the aforementioned structures and methods without departing fromthe concepts of the present disclosure, and, further, it is to beunderstood that such concepts are intended to be covered by thefollowing claims, unless these claims, by their language, expresslystate otherwise. Further, the claims, as set forth below, areincorporated into and constitute part of this Detailed Description.

What is claimed is:
 1. An electro-opticelement of a display of avehicle, comprising: a first substantially transparent substratedefining a first surface and a second surface, wherein a first edgeextends around the first substrate; a second substantially transparentsubstrate defining a third surface and a fourth surface, wherein asecond edge extends around the second substrate; a primary seal disposedbetween the first and second substrates, the seal and the first andsecond substrates defining a cavity therebetween, wherein at least oneof the first and second edges includes a stepped formation proximate theseal to define a channel; an electrical bus positioned within thechannel; and an electro-optic material positioned within the cavity. 2.The electro-optic element of claim 1, wherein the second edge is steppedin an inboard direction to define the channel.
 3. The electro-opticelement of claim 1, wherein both the first and second edges are steppedto define the channel.
 4. The electro-optic element of claim 3, furthercomprising: a first electrical bus positioned proximate the firststepped edge; and a second electrical bus positioned proximate thesecond stepped edge, wherein the first and second electrical buses areelectrically isolated.
 5. The electro-optic element of claim 4, whereinthe seal is positioned between the first and second electrical buses. 6.The electro-optic element of claim 1, wherein the cavity has a spacingbetween about 20 μm and about 75 μm.
 7. The electro-optic element ofclaim 1, wherein an electrical connection extends into the channel, theelectrical connection comprises a polymeric film with a metalliccoating.
 8. The electro-optic element of claim 1, wherein an electricalconnection extends into the channel and a thickness of the electricalconnection is greater than a spacing of the cavity.
 9. Anelectro-opticelement, comprising: a first substantially transparentsubstrate defining a first surface and a second surface, wherein a firstedge extends around the first substrate; a second substantiallytransparent substrate defining a third surface and a fourth surface,wherein a second edge extends around the second substrate; a primaryseal disposed between the first and second substrates, the seal and thefirst and second substrates defining a cavity therebetween, wherein thecavity has a thickness between the first and second substrates of lessthan about 75 μm and the second edge includes a stepped formation in aninboard direction to define a channel; a conductive bus positionedwithin the channel and extending substantially over the second edge; andan electro-optic material positioned within the cavity.
 10. Theelectro-optic element of claim 9, wherein the seal is positioned inboardof the channel.
 11. The electro-optic element of claim 10, wherein thechannel is wider than it is tall.
 12. The electro-optic element of claim10, wherein the channel is taller than it is wide.
 13. The electro-opticelement of claim 9, wherein the electro-optic material is anelectrochromic material.
 14. The electro-optic element of claim 9,wherein an electrical bus is positioned within the channel and extendssubstantially around the second substrate.
 15. The electro-optic elementof claim 9, wherein the first edge is stepped in an inboard directionsuch that the channel is defined by the first and second stepped edgesand an electrical bus substantially fills the channel.
 16. Anelectro-optic element, comprising: a first substantially transparentsubstrate defining a first surface and a second surface, wherein a firstedge extends around the first substrate; a second substantiallytransparent substrate defining a third surface and a fourth surface,wherein a second edge extends around the second substrate, wherein thesecond edges is set inboard of the first edge to define a channel; aconductive bus positioned within the channel, the conductive busdefining an exterior curved surface which substantially intersects thefourth surface; a primary seal disposed between the first and secondsubstrates, the seal and the first and second substrates defining acavity therebetween; and an electro-optic material positioned within thecavity.
 17. The electro-optic element of claim 16, wherein theconductive bus comprises a silver epoxy.